Motor vehicle door module comprising a window regulator system

ABSTRACT

The invention relates to a door module ( 1 ) of the type formed by a single part and from a single injected material, which module comprises a substantially flat supporting face ( 2 ) and at least one guide rail ( 34 ) of a window regulator system, said rail ( 34 ) being intended to guide and maintain a motor vehicle window supporting device ( 32 ). The rail ( 34 ) forms at least part of one of one of the side end parts ( 4 ) of the supporting face ( 2 ), said rail ( 34 ) extending continuously with the rest of the module ( 1 ) and forming a projection ( 40 ) in relation to the supporting face ( 2 ). The rail ( 34 ) extends in at least two planes different from the plane of the supporting face ( 2 ).

The present invention relates to a door module for a motor vehicle,formed by a single part and from a single injected material, said modulecomprising a substantially flat supporting face and at least one guiderail of a window regulator system, such a rail being designed to guideand maintain a motor vehicle window supporting device.

Door modules are parts, for example made from plastic, intended to bemounted on the door of a motor vehicle so as to contain certainfunctions of the door therein while lightening it. These functions arefor example the window regulator system, the inner handle, a speakersupport, electrical cable holders, etc.

The door module for example incorporates a guide rail for a windowregulator system making it possible to guide the translation of asupport device of a window so as to move it between an open position anda closed position.

Document FR-2 920 183 for example describes a door module comprising aguide rail formed by a rib, i.e., a straight segment protruding from theflat surface of the door module. Such a rib is not satisfactory, as itonly makes it possible to maintain the support device in one direction,i.e. a direction substantially perpendicular to the direction in whichthe rib extends. This unidirectional support is too fragile, and thesupport device may leave the rib, for example in case of impact, thewindow then no longer being supported by the door module.

The door module also generally incorporates a sealing ring making itpossible to ensure sealing with the door of the vehicle when the moduleis mounted. Such a seal extends over the entire periphery of the module,including beyond the rails, and is made in a single piece with the doormodule. However, such a seal prevents simple production of the doormodule if one also wishes for the door module to comprise a guide railwith a more complex shape than a rib so as to ensure effectivemaintenance of the support device. In fact, in that case, if one wishesto make the door module in a single piece, it is necessary to providemoving drawers to form the rail with a complex shape protruding relativeto the flat surface of the module and the sealing ring. The injectionmold is then complicated by the presence of several drawers in additionto the two mold parts, and the method for producing the module requiressteps for controlling the movement of the drawers in addition to theopening and closing of the mold. The door module is then more expensiveto produce and the production rhythms are reduced.

One aim of the invention is to offset these drawbacks by proposing adoor module comprising a guide rail ensuring effective maintenance ofthe window support device and capable of incorporating a large number offunctions of the door while being easy to produce in a single injectionoperation.

To that end, the invention relates to a door module of theaforementioned type, wherein said rail forms at least one part of one ofthe lateral end parts of the supporting face, said rail extendingcontinuously with the rest of the module and forming a projection inrelation to the supporting face, said rail extending in at least twoplanes different from the plane of the supporting face.

Providing a rail extending in at least two planes different from theplane of the supporting face makes it possible to maintain the windowsupport device effectively, both in the direction in which the railextends and in the directions perpendicular to that direction.Furthermore, since the rail is part of one of the lateral end parts ofthe module, it is not necessary to provide moving drawers in the mold toproduce the rail. The door module is therefore extremely simple, fastand inexpensive to produce.

According to other aspects of the door module:

-   -   the door module comprises two guide rails of a window regulator        system, each rail forming at least one part of a lateral end        part of the supporting face, said rails extending continuously        with the rest of the module and each forming a projection        relative to the supporting face, such rails each extending in at        least two planes different from the plane of the supporting        face;    -   the rail comprises a first branch extending substantially in a        transverse plane from the supporting face and a second branch        extending substantially in a longitudinal plane from the first        branch;    -   the door module comprises at least one speaker support formed by        an opening in the supporting face;    -   the door module comprises at least one support for receiving an        inside door handle;    -   the door module comprises at least one means for supporting        actuating means of the window regulator system;    -   the door module comprises at least one means for receiving        functional cables of the motor vehicle;    -   the door module comprises means for reinforcing the module, said        means being formed by a plurality of ribs protruding from the        supporting face;    -   the single injected material is a polypropylene-based plastic        reinforced with glass fibers.

The invention also relates to a motor vehicle door comprising an openingfor receiving a door module, a door module as described above beingfixed in said receiving opening, a window regulator system beingassembled on said door module, said system comprising at least onedevice for supporting a window slidably mounted on the rail of the doormodule.

The invention also relates to a method for producing a door module asdescribed above, comprising a single step for injecting a singlematerial into an injection mold comprising only two mold parts and astep for stripping the module by separating the two parts of the mold.

Other aspects and advantages of the invention will appear upon readingthe following description, which is provided as an example and done inreference to the appended drawings, in which:

FIG. 1 is a diagrammatic perspective illustration of a door moduleaccording to a first embodiment of the invention,

FIG. 2 is a diagrammatic perspective illustration of the door module ofFIG. 1 received in a motor vehicle door,

FIG. 3 is a diagrammatic perspective illustration of a door moduleaccording to a second embodiment of the invention,

FIG. 4 is a diagrammatic cross-sectional view along axis IV-IV of FIG.3, a window support device being received on the guide rail,

FIG. 5 is a view similar to FIG. 4 of one alternative embodiment.

In the description, the term “longitudinal” is defined relative to theplanes parallel to the plane in which the supporting face of the doormodule extends, and the term “transverse” is defined relative to theplanes perpendicular to the longitudinal planes.

In reference to FIGS. 1 and 3, a door module 1 is described that is madefrom a single part and from a single injected plastic. “Made from asingle part” means that the door module 1 is a single unit, all of thecomponent elements thereof being made simultaneously, continuously in asame piece. “From a single plastic material” means that a single productis used to perform the injection of the door module 1, even if thatproduct is a mixture of several different materials.

In this way, the door module 1 according to the invention is made from aplastic. The door module for example comprises glass fiber reinforcedpolypropylene. The material used is for example known under the acronymPP LGF (polypropylene long glass fibers).

The door module comprises a substantially flat supporting face 2extending longitudinally between two lateral end parts 4 forming theouter edges of the door module 1 along the width thereof. The supportingface 2 may have varied shapes depending on the architecture of the doorand the number of functions included in the door module 1. As anexample, the supporting face 2 shown in FIG. 1 is in the shape of asquare surrounding a central opening 6, while the supporting face 2shown in FIG. 3 is substantially continuous between the lateral endparts 4 and is substantially X-shaped. Other shapes can of course alsobe considered.

As shown in FIG. 2, the door module 1 remains fixed to a motor vehicledoor 8, in particular in an opening 10 thereof. To that end, the doormodule 1 comprises means for fixing to the door, such as fastening tabs12 or threaded barrels 14.

Aside from these fastening means, the door module 1 makes it possible toincorporate a large number of functions of the door by injecting in asingle part means making it possible to perform those functions duringthe injection of the door module.

In this way, the door module for example comprises part of a windowregulator system, described later, a speaker support 16, a support forreceiving an inside handle 18, at least one means 20 for receivingfunctional cables of the motor vehicle, such as electrical cables. Otherfunctions may of course be included on the door module, such as supportmeans for an armrest, a parcel tray, etc.

The speaker support 16 is for example formed by an opening 22 formed inthe supporting face 2 and comprising means for fitting the speaker asshown in FIG. 1 or openings or barrels for fastening the speaker asshown in FIG. 3.

The support 18 for receiving an inside handle is for example formed byone or more fastening points making it possible to mount the innerhandle rotatably.

The means 20 for receiving functional cables is for example formed by ahook or notch 24 making it possible to retain a bundle of cables.According to one embodiment, several hooks or notches 24 are formed soas to form a cable path making it possible to orient and distribute thecables optimally.

The door module also comprises reinforcing means 26 for the module so asto give it the required stiffness. According to the embodiments shown inthe figures, these reinforcing means 26 are formed by a plurality ofribs 28, 29 protruding substantially transversely from one side of thesupporting face 2. The ribs 28, 29 are distributed optimally toguarantee the desired stiffness. According to the embodiment shown inFIGS. 1 and 2, the ribs 28 extend substantially in a sawtooth patternbetween the transversely protruding edges of the supporting face 2 anddelimiting that supporting face, such as the lateral edges 4 and theedges 30 extending over the periphery of the central opening 6. The ribs28 therefore extend slanted relative to the lateral edges 4 and limitthe bending of a section substantially perpendicular to those edgesunder the action of a transverse effect. It should be noted that thelateral edges 4 and the edges 30 formed by ribs with a greater heightthan the ribs 28 create part of the stiffening means 26. In fact, saidedges 4, 30 limit the bending of the supporting face 2 in the directionparallel thereto in the case of a transverse force. According to theembodiment shown in FIG. 3, ribs 27, 28, 29 extend over part of thesurface of the supporting face 2 to create the reinforcing means 26. Theribs 27 are for example distributed “in a star” from certain fasteningpoints of the door module 1, other ribs 28 extending through thesupporting face 2 or slanted relative to the lateral edges 4 to increasethe stiffness of the module. The ribs 29 extend parallel to the lateraledges 4 and limit the bending thereof. Such ribs 27, 28, 29 make itpossible to increase the stiffness of the door module 1 simply, withoutadding a significant weight thereto.

The notches 24 forming means for receiving functional cables are forexample formed in some of the ribs 28, as shown in FIG. 1.

The window regulator system partially formed with the door module 1 isfor example a cable or Bowden tube system. In such a system, at leastone support device 32 (partially shown in FIG. 4) for a window (notshown) is translated along at least one guide rail 34 using at least onecable (not shown) actuated by an actuating means such as a drum (notshown) actuated manually or by a motor (not shown). Depending on thearrangement of the window regulator system, the cable(s) may pass aroundone or more pulleys (not shown) arranged appropriately. Translating thesupport device 32 makes it possible to move the window from an openposition to a closed position and vice versa.

The door module 1 comprises, incorporated in a single part with thesupporting face 2, the guide rail 34 and the support means 36 for themeans for actuating the window regulator system and potentially supportmeans 38 for the pulleys. The cable receiving means 20 may also be usedfor the passage of the cables actuating the window regulator system.

According to the embodiment shown in FIGS. 1 and 2, the door module 1comprises a single guide rail 34, for a so-called “single-lift” windowregulator system. This rail 34 forms at least one part of one of thelateral end parts 4 of the supporting face 2 and forms a projection 40relative to the supporting face 2, i.e., the rail 34 protrudes relativeto the supporting face 2. According to one embodiment, the rail 34 formsthe entirety of one of the lateral end parts 4 of the supporting face.

According to the embodiment shown in FIG. 3, the door module 1 comprisestwo guide rails 34, for a so-called “double-lift” window regulatorsystem. Each rail 34 forms at least one part of a lateral end part 4 ofthe supporting face 2, i.e., the two lateral end parts 4 partially forma rail 34. These rails each form a projection 40 relative to thesupporting face 2, i.e., the rails 34 protrude relative to thesupporting face 2. According to one embodiment, each rail 34 forms theentirety of one of the lateral end parts 4 of the supporting face 2.

A guide rail 34 will now be described in more detail.

The rail 34 forms part of one of the lateral end parts 4 of thesupporting face 2, i.e., the rail 34 extends toward the outside of thesupporting face 2 in the longitudinal direction and there is no otherelement of the door module 1 beyond the rail in that longitudinaldirection.

The rail 34 extends in at least two planes different from the plane inwhich the supporting face 2 extends. Thus, as shown in FIG. 4, the rail34 for example comprises a first branch 42 extending substantially in atransverse plane from the supporting face 2 continuously with saidsupporting face 2, said branch 42 forming the projection 40, and asecond branch 44 extending substantially in a longitudinal plane,parallel to the plane of the supporting face 2, from the first branch 42and toward the outside of the support module 1. Since the rail 34extends continuously with the supporting face 2, no opening is providedin the rail 34 or at the transition between the rail 34 and thesupporting face 2. This avoids having to provide means for sealing suchan opening. The first branch 42 of course participates in strengtheningthe supporting face 2. This is done similarly to the ribs 29 due to itsarrangement in a transverse plane and its direction combined with thelateral edge 4.

The support device 32 is configured to surround the rail 34, as shown inFIG. 4, and therefore comprises an opening 46 having a slit 48 extendingtransversely emerging over a slit 50 extending longitudinally. It willeasily be understood that such a shape of the rail 34 and support device32 makes it possible to ensure maintenance in the longitudinal andtransverse directions of the window support device 32 so as to ensureeffective and robust support for the window. In this way, the rail 34ensures both the translational guiding and maintenance of the supportdevice 32.

FIG. 5 shows an alternative embodiment of the diagrammatic illustrationof FIG. 4. The lateral edge 4 of the supporting face has a rail 34provided with a support device, or slider, 32. The slider 32 showndiagrammatically is of a known type. The transverse and longitudinalslits 48, 50 have bosses suitable for coming into contact, with acertain resilience, respectively on the first and second branches 42, 44of the rail. In this way, the slider 32 has limited and opposite contactareas with each rail plane and slides without play.

It will be noted that the slider 32 has a large face 32 a adjacent tothe supporting face 2. The slider 32 is therefore prevented fromrotating around the rail 34, here in the counterclockwise direction, andthe end of the supporting face 2 participates in the guiding.

A slanted rib 28 and four ribs 29 parallel to the edge 4 are shown inFIG. 5. As in the case of the corresponding ribs of the embodiment ofFIG. 3, these ribs 28, 29 form reinforcing means.

The rib 29 parallel to the end of the supporting face 2, on the right inFIG. 5, itself forms the lateral edge 4. Thus, the lateral edge 4comprises a lateral reinforcing rib that extends at least partiallyalong that edge, and preferably over the entire length of the rail 34.This makes it possible to concentrate the reinforcing means in asignificantly stressed portion of the door module due to the presence ofthe rail 34 and the forces exerted by the slider 32. It should be notedthat the windows of current vehicles are often rounded. The rail mustthen also be rounded and preserve the geometry of that curve andpreserve the geometry of that curve during movements of the window.

Still regarding the right-hand parallel rib 29, it must be noted that itextends transversely on either side of the plane of the supporting face2 and that the portion thereof situated on one side of that plane formsthe first branch 42 of the guide rail. In this way, a portion of thedoor module, i.e., the first branch 42, performs both a guiding functionand a strengthening function. The same is true for the end portion ofthe supporting face 2 along which the face 32 a of the slider slides andwhich is reinforced by two parallel ribs 29. This makes it possible tosave plastic and therefore reduce the weight of the module.

Still with the aim of stiffening and saving weight, corner pieces 52 andreinforcing fins 54 are provided inside and outside the corner betweenthe first and second branches 42, 44 of the rail 34.

Other rail shapes 34 may be considered. In particular, a third branchextending in a transverse plane may be added so as to extend from thefree part of the second branch 44. It is possible to provide a railcorresponding to a standard rail shape already used by automobilebuilders. In this way, it would not be necessary to provide a windowsupport device, or slider, specific to the rail 34 of the support module1. This would make it possible to limit the modifications that must bemade to existing production lines to produce the support device or thewindow regulator system in general.

Due to the absence of sealing rings on the periphery of the door module,there is no element of that module that extends beyond the rail(s) 34 inthe longitudinal direction toward the outside of the supporting face 2.This makes it possible to produce the door module described aboveparticularly simply from a mold simply having two mold parts defining amolding cavity between them when the parts are pressed against eachother. In fact, the shape of the rail allows natural stripping of thedoor module by simply separating the two mold parts from each other. Itis therefore not necessary to provide an additional movable drawer forstripping the rail 34. This is also applicable for more complex railshapes, as long as the stripping can be done by simply separating themold parts.

It is possible to have a localized element that extends beyond the rail,such as the speaker support shown in FIG. 3. In that case, only a smalllocalized drawer is necessary to strip the rail at that support.However, that drawer is small and does not extend over the entire lengthof the rail, as is the case when the sealing ring is provided. Thestripping therefore remains relatively simple and inexpensive.

Furthermore, the lack of sealing rings makes it possible to savesubstantially on material and significantly lighten both the door moduleproduced and the door structure comprising that door module. In fact,aside from the material saved in the module, the lack of a seal makes itpossible to eliminate the bearing track for that sealing ring on thelining of the door, which also makes it possible to save in terms ofmaterial and mass. As an example, such a door module makes it possibleto lighten a vehicle comprising a door equipped with a door module asdescribed above by 3 to 4 kg relative to the mass of a motor vehicleequipped with traditional doors. The sealing between the door module 1and the door 8 may be ensured traditionally, for example using a sheetof impermeable material, which is easily placed and lightweight.

The door module described above is therefore particularly simple andcost-effective to produce, while offering effective maintenance of thewindow support device and making it possible to reduce the general massof the motor vehicle door.

The door module also makes it possible to combine a large number offunctions of the vehicle door, simply and configurably, by simplymodifying the shape of the injection cavity.

1. A door module for a motor vehicle, formed by a single part and from asingle injected material, said module comprising a substantially flatsupporting face and at least one guide rail of a window regulatorsystem, said rail being usable to guide and maintain a motor vehiclewindow supporting device, characterized in that said rail forms at leastone part of one of the lateral end parts of the supporting face, saidrail extending continuously with the rest of the module and forming aprojection in relation to the supporting face, said rail extending in atleast two planes different from the plane of the supporting face.
 2. Thedoor module according to claim 1, characterized in that it comprises twoguide rails of a window regulator system, each rail forming at least onepart of a lateral end part of the supporting face, said rails extendingcontinuously with the rest of the module and each forming a projectionrelative to the supporting face such rails each extending in at leasttwo planes different from the plane of the supporting face.
 3. The doormodule according to claim 1, characterized in that the rail comprises afirst branch extending substantially in a transverse plane from thesupporting face and a second branch extending substantially in alongitudinal plane from the first branch.
 4. The door module accordingto claim 1, characterized in that it comprises at least one speakersupport formed by an opening in the supporting face.
 5. The door moduleaccording to claim 1, characterized in that it comprises at least onesupport receiving an inside door handle.
 6. The door module according toclaim 1, characterized in that it comprises at least one means forsupporting actuating means of the window regulator system.
 7. The doormodule according to claim 1, characterized in that it comprises at leastone means for receiving functional cables of the motor vehicle.
 8. Thedoor module according to claim 1, characterized in that it comprisesmeans for reinforcing the module, said means being formed by a pluralityof ribs protruding from the supporting face.
 9. The door moduleaccording to claim 1, characterized in that at least the lateral endpart having the guide rail comprises a transverse reinforcing ribextending over at least part of said end part, and preferably over theentire length of said guide rail.
 10. The door module according to claim1, characterized in that it comprises a reinforcing rib extendingtransversely on either side of the supporting face, a portion of saidreinforcing rib situated on one side of the supporting face forming afirst branch of the guide rail.
 11. The door module according to claim1, characterized in that the single injected material is apolypropylene-based plastic reinforced with glass fibers.
 12. A motorvehicle door, said door comprising an opening with a door moduleaccording to claim 1 being received in said opening, a window regulatorsystem being assembled on said door module, said system comprising atleast one device for supporting a window slidably mounted on the rail ofthe door module.
 13. A method for producing a door module according toclaim 1, comprising a single step for injecting a single material intoan injection mold comprising only two mold parts and a step forstripping the module by separating the two parts of the mold.